U.S. patent number 3,552,328 [Application Number 04/718,567] was granted by the patent office on 1971-01-05 for pallet.
This patent grant is currently assigned to Sullifoam, Inc.. Invention is credited to Matthew A. Sullivan.
United States Patent |
3,552,328 |
Sullivan |
January 5, 1971 |
PALLET
Abstract
A pallet is provided having spaced apertured blocks of rigid
foam polymeric material bonded or otherwise secured between layers
of corrugated paperboard. The pallet may be rendered substantially
waterproof. In one embodiment, C-shaped support members may be
connected to at least some of the edges of the pallet. Openings may
be provided in the C-shaped support members to permit the tines of
a fork lift truck to engage the pallet to effect movement thereof.
When the C-shaped support members are secured to each of the edges
of the pallet, the pallet will be rendered substantially
waterproof. In another embodiment, the bottom layer of corrugated
paperboard may be eliminated and the top layer utilized to envelop
some of the blocks. An intermediate strip of corrugated paperboard
may be used to provide a base for the remaining blocks.
Inventors: |
Sullivan; Matthew A. (Elkins
Park, PA) |
Assignee: |
Sullifoam, Inc. (Willow Grove,
PA)
|
Family
ID: |
27089284 |
Appl.
No.: |
04/718,567 |
Filed: |
April 3, 1968 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
|
622808 |
Mar 13, 1967 |
3380403 |
|
|
|
Current U.S.
Class: |
108/51.3;
108/57.1 |
Current CPC
Class: |
B65D
19/0026 (20130101); B65D 19/0028 (20130101); B65D
19/0095 (20130101); B65D 19/0012 (20130101); B65D
2519/00069 (20130101); B65D 2519/00373 (20130101); B65D
2519/00557 (20130101); B65D 2519/00562 (20130101); B65D
2519/00019 (20130101); B65D 2519/00572 (20130101); B65D
2519/00343 (20130101); B65D 2519/00318 (20130101); B65D
2519/00278 (20130101); Y10S 108/901 (20130101); B65D
2519/00288 (20130101); B65D 2519/00099 (20130101); B65D
2519/00432 (20130101); B65D 2519/00273 (20130101); B65D
2519/00104 (20130101); B65D 2519/00054 (20130101) |
Current International
Class: |
B65D
19/00 (20060101); B65d 019/18 () |
Field of
Search: |
;108/51--58 ;52/614--625
;248/188 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Gay; Bobby R.
Assistant Examiner: Finch; Glenn O.
Parent Case Text
This application is a continuation-in-part of my prior application
Ser. No. 622,808 filed Mar. 13, 1967, for "Pallet" now U.S. Pat.
No. 3,380,403.
Claims
I claim:
1. A pallet comprising a plurality of spaced molded blocks of rigid
foam polymeric material having smooth opposed major surfaces, a
layer of corrugated paperboard fixedly secured to the top surfaces
of said blocks, said layer of corrugated paperboard including
sleeves at opposite ends thereof for encircling at least some of
said foam polymeric blocks, said sleeve being integral with said
layer, said sleeve including sidewalls adjacent the sides of said
some of said foam polymeric blocks, said sleeves further including
bottom walls for contacting the bottom faces of said some of said
foam polymeric blocks, a further strip of corrugated paperboard
fixedly secured only to the bottom faces of other of said foam
polymeric blocks, said further strip having substantially the same
width and length as the bottom wall of said sleeve, and said
sidewalls of said sleeve cooperating with said foam polymeric
blocks to resist deformation of said pallet.
2. A pallet as set forth in claim 1 wherein said layer of
corrugated paperboard has score lines therein to facilitate forming
of said sleeves, said layer of corrugated paperboard being wax
coated to render said pallet substantially waterproof, said sleeve
including additional sidewalls for contacting other side of some of
said foam polymeric blocks, said other sidewalls having flaps
connected thereto, and means securing said flaps to the under side
of said layer of corrugated paperboard.
3. A pallet as set forth in claim 1 wherein the bottom of said
pallet is open to permit the tines of a lifting vehicle to travel
on the ground and be positioned under said pallet, said pallet
being open between said sleeves and said further strip of
corrugated paperboard, said pallet between said sleeves and said
further strip of corrugated paperboard being substantially composed
of a single thickness of corrugated paperboard.
Description
My prior application was directed primarily to an expendable pallet
which was to be used once and thereafter discarded. The pallet set
forth in my previous application has filled a long existing need in
industry and is excellent for its intended use. However, due to the
superior features of my expendable pallet, such as low cost and
weight factors, there has been an increasing demand that the pallet
has been made sturdier, more durable and substantially waterproof.
Accordingly, the present invention is directed to an inexpensive,
lightweight, substantially waterproof, sturdy and durable pallet
which may be reused many times without substantial deterioration of
the pallet.
In plants where pallets are utilized to convey goods along a
production line, and the pallets are made of wood, the pallets
present a substantial problem. Because of the weight of wooden
pallets, it has generally been necessary to provide a man at the
end of a production line to remove the pallet from the conveyor
line. In many instances, one man can service two production lines
to remove and stack the cumbersome and heavy wooden pallets.
Furthermore, intraplant use of the pallets has substantially
increased to convey goods throughout various locations in a single
plant. Accordingly, it is desirable to provide a pallet having the
features of my expendable pallet but which is adapted to be reused
many times without noticable deterioration of the pallet.
It is an object of the present invention to provide a pallet which
is light in weight and inexpensive to manufacture and yet sturdy
and durable in use. This is accomplished by providing blocks of
rigid foam ply polymeric material which are bonded or otherwise
secured between layers of corrugated paperboard. The blocks of
polymeric material are provided with a plurality of holes
therethrough. The provision of such holes has various advantages.
Thus, the provision of such holes enables the blocks to be molded
more consistently and provides for more uniform heat distribution
so that the blocks may be molded at a faster cycle as compared with
solid blocks. In addition, the holes will trap air when sandwiched
between layers of paperboard and thereby offer resistance to
crushing under the load supported thereon.
In one embodiment, after the pallet has been assembled, C-shaped
support members may be secured to the side edges thereof. The
C-shaped support members prevent damage to the blocks of polymeric
material should the pallet be dropped or otherwise mishandled. The
C-shaped support members may render the pallet substantially
waterproof. Openings may be provided in the C-shaped support
members to permit the tines of a fork lift truck to be inserted
between the layers of corrugated paperboard. Strips integral with
the C-shaped members may project inwardly adjacent the openings and
further provide additional protection for the polymeric blocks.
Hence, the strips will minimize damage and tend to prevent the
tines of a fork lift truck from destroying substantial portions of
the blocks should the tines be improperly inserted into the
openings in the C-shaped support members.
The C-shaped support members may be stapled or bonded to the layers
of corrugated paperboard. In order to provide additional
protection, the C-shaped support members may be glued or bonded to
the exposed edges of the polymeric blocks to provide additional
support thus obviating crushing of the pallet.
In another embodiment, the bottom layer of corrugated paperboard is
eliminated. The top layer of paperboard is provided with
appropriate score lines and envelops at least some of the blocks of
polymeric material. When the blocks are utilized to support the
center portion of the top layer, an intermediate strip of cardboard
may be utilized to provide a base for such blocks. C-shaped support
members may be utilized with this embodiment to further increase
the strength and durability of the pallet.
For the purpose of illustrating the invention, there is shown in
the drawings forms which are presently preferred; it being
understood, however, that this invention is not limited to the
precise arrangements and instrumentalities shown.
FIG. 1 is a top plan view of one embodiment of the pallet of the
present invention;
FIG. 2 is a side elevation view taken along line 2-2 of FIG. 1;
FIG. 3 is a perspective view of one of the blocks of rigid foam
polymeric material;
FIG. 4 is a top plan view of an alternate construction of the
embodiment of FIG. 1 of the pallet of the present invention;
FIG. 5 is a side elevation view of the pallet of FIG. 4;
FIG. 6 is a partial section view taken along line 6-6 of FIG.
5;
FIG. 7 is a top plan view of another embodiment of the pallet of
the present invention;
FIG. 8 is a bottom plan view of the pallet of FIG. 7; and
FIG. 9 is a section view taken along line 9-9 of FIG. 7.
Referring now to the drawings in detail, wherein like numerals
indicate like elements throughout the several views, there is shown
in FIG. 1 a pallet designated generally as 10. The pallet 10 may be
of any desired size. The pallet 10 includes a top layer of
corrugated paperboard 12 and a bottom layer of corrugated
paperboard 14.
The layers of paperboard 12 and 14 are superimposed over one
another and are bonded to opposite faces of a plurality of
longitudinally and laterally spaced blocks of rigid foam polymeric
material 16, 18, 20, 22, 24, 26, 28, 30 and 32. The blocks of
polymeric material are preferably made from foam polystyrene. The
blocks 16, 18, 20 and 22 are disposed at the corners of the pallet.
Blocks 16, 30 and 18 form a row along one side of the pallet.
Blocks 20, 32 and 22 form a row along the opposite side of the
pallet. A central row of blocks is formed by blocks 24, 26 and
28.
Channels 34, 36, 38 and 40 are provided so that the prongs or tines
of a fork lift truck may be inserted thereinto to facilitate
lifting and transferring a loaded pallet. The opposite faces of the
blocks of foam polymeric material are adhesively bonded to the
inner surfaces of the corrugated paperboard layers 12 and 14 by any
suitable adhesive such as a commercially available rubber-base
adhesive. It will be noted that the top and bottom faces of the
blocks have surface area which is substantially larger tan the
surface area of any of the sides or end faces of the blocks. In
this manner, maximum support for layers 12 and 14 of corrugated
paperboard is provided.
Each of the blocks has a plurality of holes extending therethrough.
Referring to FIG. 3, block 20 is provided with six holes extending
therethrough from the top face 44 to the bottom face thereof.
Blocks 16, 30, 18, 22 and 32 are identical with block 20. Blocks
24, 26 and 28 are identical with block 20, except that they are
larger and have a larger number of holes extending therethrough.
For example, as shown in FIG. 1, the blocks 24, 26 and 28 will have
nine holes extending therethrough.
The holes 42 in block 20, for example, enable the block 20 to be
more consistently molded due to the holes providing for uniform
heat distribution. As a result thereof, the blocks may be molded at
a faster cycle rate than if the blocks were solid. It is desirable
to mold the blocks since molding will produce a smooth surface
finish. If the blocks are cut to size, a rough surface is presented
requiring about 50 percent more glue than bonding the blocks to
layers 12 and 14 of corrugated paperboard. Furthermore, since the
blocks are sandwiched between layers of corrugated paperboard, air
is trapped in the holes. As a result thereof, the blocks offer more
resistance to crushing forces since the air will tend to be
compressed as the crushing forces increase. The compressed air in
the holes will resist deformation of the blocks.
The pallet 10 is provided with C-shaped support members 46 and 48
which are connected to the side edges thereof. The C-shaped support
members 46 and 48 are substantially identical and hence only member
46 will be discussed in detail. The support members 46 comprises
legs 50 and 52 which extend outwardly from an interconnecting web
51. The leg 50 is adapted to overlie layer 12 and leg 52 is adapted
to overlie the layer 14. The legs 50 and 52 may be secured to the
layers 12 and 14, respectively, by stapling, bonding or any other
desired manner.
Preferably, the members 46 and 48 are also made of paperboard and
may be made of corrugated paperboard. The exterior surface of each
of the members may be wax coated to render the members water
repellent The corrugated layers 12 and 14 may also be provided with
wax-coated exterior surfaces to repel water. However, the flutes of
the corrugated paperboard are exposed along the edges of the board
and are subject to attack by water.
In the embodiment of FIG. 1, the C-shaped support members are
attached to the sides of the pallet 10. Accordingly, the members 46
and 48 prevent water from contacting the flutes of the corrugated
layers 12 and 14 from the sides thereof. It is to be noted that the
blocks do not transmit water, and accordingly, the only way in
which the top layer of corrugated paperboard could be destroyed by
water is if the pallet were placed in several inches of water.
However, even when this occurs, the preferred adhesive between the
paperboard and the blocks will be water resistant and hence the
pallet will still function in the desired manner.
Member 46 may be adhesively secured to the side edges of the blocks
20, 32 and 22 by a layer of adhesive 54. By adhesively securing a
portion of the interior face of the web 51 to the blocks, the
member 46 will cooperate with the blocks to resist deformation of
the pallet 10. In the embodiment of FIG. 1, the members 46 and 48
do not have any openings therein and the tines of a fork lift truck
must engage the pallet in the openings 34, 36, 38 or 40 on the
opposite ends of the pallet 10.
The legs 50 and 52 extend inwardly a substantial distance on the
pallet 10 in order to increase the sturdiness and durability of the
pallet. The ends of the legs 50 and 52 may lie in substantially the
same vertical plane which encompasses the innermost edges of the
blocks 20, 32 and 22.
An alternate construction of the embodiment of FIG. 1 is
illustrated in FIGS. 4--6. The pallet of FIG. 4 is generally
designated as 10'. The pallet 10' is identical with pallet 10,
except as will be made clear hereinafter. Hence, corresponding
primed numerals are provided. C-shaped support members 56 and 58
are provided for the ends of the pallet 10'. The C-shaped support
members 46', 48', 56 and 58 are provided with mitered edges so that
a mitered joint is provided at each of the corners of the pallet.
Since the members 46' and 48' are identical, only 46' will be
discussed in detail.
Support member 46' has openings 60 and 62 therein. The openings 60
and 62 are identical and hence opening 60 will be discussed in
detail. The C-shaped member 46' is die-cut along lines 64 and 66.
The C-shaped member 46' is scored along lines 68 and 70. The score
lines 68 and 70 permit the die-cut material to be bent thereat.
Intermediate the score lines 68 and 70, a die cut is provided so
that the material between the score lines 68 and 70 and the die-cut
lines 64 and 66 form individual strips 72 and 74. The strips 72 and
74 are bent inwardly as shown in Figure 4. The strips 72 and 74 are
adjacent one edge of the blocks 20' and 32', respectively, and
provide protection for the blocks. Hence, if one of the tines of a
fork lift truck is improperly inserted into the opening 60, strips
72 and 74 will be contacted prior to contact with the blocks and
will provide protection for the blocks.
Inwardly projecting strips 76 and 78 are provided adjacent the
opening 62. The member 48' is also provided with openings similar
to 60 and 62 and with inwardly projecting strips as is shown in
FIG. 4. Alternatively, the openings may be die-cut into the support
members and all inwardly projecting strips eliminated.
The support members 56 and 58 are substantially identical. The
members 56 and 58 are similar to the members 46 and 48 which were
described in detail with reference to FIGS. 1 and 2. The members 56
and 58 may also each be provided with openings similar to openings
60 and 62 in the support member 46'.
The inwardly projecting legs of the support members 46', 48', 56
and 58 extend inwardly a substantial distance on the pallet 10' in
order to provide support for the pallet. The ends of the legs of
the support member 56 lie in substantially the vertical plane which
is defined by the innermost vertical edge of the block 24. The legs
of the support members 46' and 48' will preferably extend inwardly
the same distance as the legs of the support members 56 and 58 as
shown in FIG. 4.
The members 46', 48', 56 and 58 cooperate to prevent water from
contacting the flutes of the corrugated layers 12 and 14 by
covering the exposed edges of the layers. The durability and useful
life of the pallet 10' is substantially increased by preventing
water from attacking the corrugated layers 12 and 14.
Each of the support members 46', 48', 56 and 58 may have adhesive
on the interior web thereof so that the support members may be
secured to the edges of the rigid foam blocks. In this manner, the
support members will cooperate with the blocks to resist
deformation of the pallet 10'. A layer of adhesive 79 is shown
connected to the interior surface of the web 51' of the support
member 46' in FIG. 6. A similar layer of adhesive is shown secured
to the interior surface of the web of the support member 58 and the
other exposed surface of the block 20'.
Another embodiment of the present invention is illustrated in FIGS.
7--9. The pallet of FIG. 7 is generally designated as 100. The
pallet 100 includes a top layer of corrugated paperboard 102.
The top layer of corrugated paperboard 102 has bonded to one face
thereof a plurality of spaced blocks of rigid foam polymeric 104,
106, 108, 110, 112 and 114. The blocks are substantially identical
in size to blocks 24, 26 and 28 of pallet 10. While six blocks are
shown, it is readily apparent that a greater or lesser number of
blocks may be utilized. The top layer of corrugated paperboard 102
has score lines therein to permit the ends thereof to envelop at
least some of the blocks of the pallet. The left and right ends of
the top layer of corrugated paperboard 102 as seen in FIG. 9 are
substantially identical. Hence, only the left end will be described
in detail.
The left end of the top layer of corrugated paperboard 102 has
score lines 116, 118, 120, 122 and 124 therein. The paperboard is
adapted to be folded along each of the score lines. When so folded,
it is readily apparent that the board provides a sleeve 126 which
envelops blocks 104 and 114 of the pallet 100. Similarly, a sleeve
128 is provided on the opposite end of the pallet 100 for
enveloping the blocks 108 and 110. The sidewalls 125 and 127 of the
sleeves 126 and 128, respectively, provide additional support for
the pallet 100. Sidewall 125 may be secured to the blocks 104 and
114 and sidewall 127 may be secured to the blocks 108 and 110 by
adhesive, staples or the like. In this manner, additional
resistance is provided to deformation of the pallet 100.
By providing the sleeves 126 and 128, the pallet 100 is rendered
substantially waterproof. The score lines tend to crush the flutes
of the paperboard and hence substantially prevent the transmission
of water throughout the layer 102. The layer 102 is preferably wax
coated to render it waterproof. A sharp bend is provided at the
score line 124 to minimize capillary action with regard to any
water which may contact the end 130 of the top layer 102.
A flap 132 is bent back on a flap 134 and both of the flaps secured
to the top layer 102. The flaps 132 and 134 may be stapled, glued
or otherwise secured to the layer 102. When glue is utilized, the
flap 132 will be first glued to the flap 134 thereafter the flap
134 may be glued to the layer 102.
A strip of corrugated paperboard 136 may be secured to the bottom
faces of the polymeric blocks 106 and 112. The strip 136 may be
glued or otherwise secured to blocks 106 and 112. It will be noted
that there is no paperboard between the sets of blocks 104 and 114;
106 and 112; and 108 and 110 on the bottom of the pallet 100.
Hence, hand lifting devices which are generally of the hydraulic
type may be rolled along the floor inserted between the sets of
blocks and utilized to move the pallet 100. The lifting device may
be inserted in channels 140, 142, 144 or 146.
It is deemed readily apparent that when six blocks are utilized,
such as in the embodiment of FIG. 7, the strip 136 may be
eliminated and the score lines provided on the sides of the layer
102 rather than at the ends thereof. When the score lines are
provided along the sides of the layer 102, one sleeve will envelop
blocks 104, 106 and 108 and the other sleeve will envelop blocks
110, 112 and 114. When polymeric blocks are centrally located under
the layer 102, it will be necessary to use at least one strip
similar to strip 136.
C-shaped support members with openings therein similar to members
46' and 48' may be utilized to further increase the strength and
durability of the pallet 100. However, the sleeves 126 and 128
which are integral with the layer 102 provide substantial support
for the pallet and the pallet 100 may be reused many times without
substantial deterioration of the pallet.
A pallet constructed in accordance with the present invention will
weigh approximately three pounds as compared with a conventional
pallet made from wood which may weigh approximately 15 pounds or
more. It will be obvious to those skilled in the art that the
weight of the pallet may vary with the size of the pallet. These
figures are based on a pallet 60 inches long and 40 inches
wide.
It should be noted with respect to the embodiment of FIGS. 1--6,
that even if the bottom layer of corrugated paperboard were to
become wet, the blocks of polymeric material would not transmit
moisture by osmosis to the top layer 14. If a nail or other sharp
surface is sticking up from the floor, the pallet 10, 10' or 100
may be positioned over the same without any substantial damage to
it. That is, a sharp object such as a nail could pierce the layer
14 and enter one of the blocks without doing any substantial damage
to the pallet. The pallet of the present invention can be tailored
to fit many different situations and conditions. The size of the
pallet and the number of blocks utilized may be varied as
desired.
I have found that suitable dimensions for block 20 and those
identical thereto are 2.times.6.times.10 inches, with holes 42
being 1.times.2 inches. Thus, the area of surface 44 is 48 square
inches. I have found that suitable dimensions for block 24 and
those identical thereto are 2.times.10.times.10 inches with holes
therein being 2.times.2 inches. Thus, the area of the top surface
of block 24 is 64 square inches. If maximum compressive strength is
desired, some of the holes in blocks 24--28 may be filled by small
blocks of wood. Other dimensions may be used for the polymeric
blocks as long as the major area is on a face joined to a layer of
corrugated paperboard. As illustrated, blocks 24, 26, 28, 104, 106,
108, 110, 112 and 114 distribute the load over a larger surface for
more even distribution.
While a wide variety of polystyrene molding material is
commercially available, I prefer to use DYLITE (Reg. T.M.) which
has the following properties:
Thermal conductivity - 0.242 at 75.degree. F. mean temperature
Density - 2 lbs. per cu. ft.
Shock resistance - theoretical energy absorption of 60--70 1bs./sq.
inch
compressive strength - 30 p.s.i.
Tensile strength - 50 p.s.i.
Water absorption - less than 0.9 percent during 48 hours
The present invention may be embodied in other specific forms
without departing from the spirit or essential attributes thereof
and, accordingly, reference should be made to the appended claims,
rather than to the foregoing specification.
* * * * *